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Improve Melt Quality Reduce Downtime! - synventive.com · MN1CB1 PRDMMNNA3 Improve Melt Quality... Reduce Downtime! Heat pipe technology is your assurance that every Synventive Nozzle

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CB1MN1PRDMMNNA3

Improve Melt Quality... Reduce Downtime!

Heat pipe technology is your assurance that every Synventive Nozzle will automatically operate at the optimum processing temperature; never too hot, never too cold. Synventive Heat Pipe technology transfers heat at uniform temperature from machine barrel to nozzle tip, eliminating “hot spots” which cause process variables.

Nozzles require a single band heater which is placed in a safe location at the back of the nozzle (machine end). The absence of multiple heaters and associated electrical hardware eliminates downtime due to failure of this equipment.

Because of built in Heat Pipe technology, Synventive Nozzles require one or no heaters for uniform temperature operation. Downtime due to electrical equipment failure is virtually eliminated.

Replaceable tips are available in steel or BeCu, and in styles for general purpose and nylon processing applications.

Synventive Nozzles are available in lengths and thread sizes to fit all popular injection molding machines.

Even for engineering materials and exceptionally long nozzle lengths, Synventive Nozzles require only one externally mounted heater band for uniform temperature operation.

Synventive Heat Pipes convert the nozzle into a super thermal conductor for unparalleled temperature uniformity.

Machine Nozzles Injection Nozzle

Every Synventive Nozzle is Guaranteed!Money back if not completely satisfied (30-day trial).

Other special features:* Synventive Mixing Nozzles-for

improved color dispersion andreduced color loading.

* Synventive Filter Nozzles - forfiltering of all plastic melts.

* Synventive BIG Nozzles - for useon very large machines with highinjection volume.

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The Superconductor for Heat Transfer!

The Heat Pipe is a hollow or evacuated chamber, inside of which is a liquid and a capillary wick, which acts as a transport device. The phenomena of evaporation, condensation, and surface-tension pumping of liquid in the wick are used to transfer latent heat of vaporization continuously from one region to another. No external forces are required to activate the Heat Pipe; only a heat source is necessary.

Cross section of a working Heat Pipe

Heat Input

Condensate Liquid Flow

Capillary Wick

Evaporation

Vapor Transport Section

Uniform Heat Output

Condensation

Important!Heaters or Not?

All Synventive Nozzles include a location for a heater band and thermocouple. If you choose to operate the Synventive Nozzle without a heater and the results are not satisfactory, Synventive recommends that a heater band and thermocouple be installed.See pages MN5-MN6 for more information.

Non-uniform temperatures in a nozzle will adversely affect the plastic melt. Conventional machine nozzles require several heater bands along their length in an attempt to maintain uniform temperatures. Downtime due to heater band failure, heater wires coated with plastic, crimped or broken thermocouple wires, etc., is common.

Machine Nozzles Heat Pipe Technology

In general, solid Copper is considered an excellent conductor of heat.But when a solid Copper bar and a Heat Pipe are placed in a beaker of boiling water, the Heat Pipe becomes uniformly hot within seconds while the end of the Copper bar will remain at room temperature.

100°c

100°c

100°c

Ambient

80°c

100°c

100°c (boiling water)

Heat Pipe Solid Copper

20 sec.

20 min.

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NOZZLE STYLES TYPE AP TYPE BIG

See page MN11 forordering information

BORE DIAMETER 12.7 mm [.500”] 19 mm [.750”]

LENGTHL1 mm 150 200 250 300 L1 mm 200 250 300 380 457 533

L2 mm 64 114 165 216 L2 mm 132 183 234 310 386 462

MINIMUM REARTHREAD DIAMETER

45 mm [1.75”] 45 mm [1.75”]

MAXIMUM REARTHREAD DIAMETER

<60 mm [2.36”] <60 mm [2.36”]

MATERIAL Standard Material - 4140 Alloy Steel (420 Stainless Steel used for

corrosive materials. Additional cost required for Stainless Steel Nozzles -

Contact Synventive)

Standard Material - 4140 Alloy Steel (420 Stainless Steel used for

corrosive materials. Additional cost required for Stainless Steel Nozzles -

Contact Synventive)

TIP STYLE Metric Inch Metric Inch

Thread 7/8-14 Thread 1-1/4-12

Rear Opening 12.7 mm .500” Rear Opening 19 mm .750”

Max. Orifice 11 mm .437” Max. Orifice 15.8 mm .625”

Material Steel or BeCu Material Steel or BeCu

BAND HEATERID Width Watts

Part NumberID Width Watts

Part Number120V 240V 120V 240V

2 1 350 81-20-102 81-20-104 2.25 2.50 1000 81-22-124 81-22-125

SPECIAL FEATURES* Heater is optional (see page MN5-MN6 for

more information on when heater is required)

* One heater band required*See Type F-BIG for filter information

*See Type M-BIG for static mixer information

Machine Nozzles Selection Guide

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NOZZLE STYLES TYPE M/M-BIG TYPE F/F-BIG

See page MN11 forordering information

Mixing Nozzles for Color Mixing Filter Nozzles for Contaminant Free Processing

BORE DIAMETER Type M19 mm [.750”]

Type M-BIG19 mm [.750”]

Type F12.7 mm [.500”]

Type F-BIG19 mm [.750”]

LENGTH

L1 = 267 mm [10.5”]L2 = 178 mm [7”]

Same as Type A/AP Same as Type BIG

L1 mm 300 380 457 533

L2 mm 234 310 386 462

MINIMUM REARTHREAD DIAMETER

45 mm [1.75”]

45 mm [1.75”] 45 mm [1.75”] 45 mm [1.75”]

MAXIMUM REARTHREAD DIAMETER

<60 mm [2.36”] <60 mm [2.36”] <60 mm [2.36”]

MATERIAL

4140 Alloy Steel 4140 Alloy Steel 4140 Alloy Steel 4140 Alloy Steel

TIP STYLE

Same asType A/AP

Same asType BIG

Same asType A/AP

Same asType BIG

BAND HEATERSame as

Type A/APSame asType BIG

Same asType A/AP

Same asType BIG

SPECIAL FEATURES *Heater is optional*Mixing element is permanently

bonded to nozzle bore formaintenance free operation

*One heater band required*M-BIG mixing elements can be ordered separately and used on conventional nozzles - see pageMN8 for machining information

*Heater is optional*Two groove styles available- see page MN7 for options

*Type F filter elements can be ordered separately - see page

MN7 for more information

*One heater band required*Three groove styles available

- see page MN7 for options*Type F-BIG filter elements can be ordered separately - see page

MN7 for more information

Machine Nozzles Selection Guide

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Nozzle with Heaters.Recommended for processing all engineering grade materials, including crystalline materials.

Special Processing Considerations

Nylon

Similar to conventional nozzles, Synventive Nozzles require special attention when processing nylon.Due to nylon’s very narrow temperature processing range, tip drooling or freezing are common processing problems. Consistent reliable processing of nylon can be easily achieved by following several simple precautions.1. Always use a Synventive Nozzle Type

that has its own heater. This enablesthe operator to adjust the nozzletemperature independently higher orlower to find the proper processingtemperature window.

2. Use a good quality temperaturecontroller (PID type recommended)in conjunction with the thermocouple threaded into the 1/4-28 T/C holeprovided in one of the hex flats on the nozzle. It is important to use atemperature controller with feedbackas opposed to a variable transformer(variac) which could allow the nozzletemperature to gradually changehigher or lower as the room, mold, or machine temperature changes.

3. There are two basic internalconfigurations of removable tips thatare generally available:a) General Purpose Style andb) Nylon Style. The Nylon Style Tipwith its reverse taper orifice shouldalways be used when processingnylon. The exception to the rule ofusing Nylon Style Tips, of course, iswhen the nozzle tip is to be usedagainst a heated sprue bushing or ahot manifold. In those cases, aGeneral Purpose Tip isrecommended.

Machine Nozzles Nozzle Types

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Nozzle Installation

As with conventional injection machine nozzles, good installation procedures are important to prevent seizing or galling of the threaded connection and to facilitate removal.This can be easily accomplished by following a few simple rules.1. Before threading the nozzle into the machine barrel or adapter be certain that both male and

female threads are clean. All traces of plastic and other material must be removed from boththe male and female threads.

2. All burrs, dings, etc., must be filed off the threads.Threads should be sufficiently clean to allow the nozzle to be threaded in completely by hand.

3. Before final assembly, coat internal and external threads with a high temperature anti-seize compound.

4. When threading a cold nozzle into a hot barrel or adapter, do not completely thighten thenozzle until the nozzle is nearly at the same temperature as the barrel or adapter.

5. The nozzle sealing surface (the face of the threaded end) and the machine’s mating face must also be inspected for dings, dents, etc., prior to assembly to prevent leakage.The same rules apply to removable tip assembly and for any high temperature, high pressure threaded connections.

Machine Barrel End CapsOccasionally, machine barrels are fitted with isolation type end caps as shown below.This type of end cap has been designed to intentionally reduce heat transfer to the machine nozzle. Synventive Nozzle Types with heaters are required when used with isolation end caps.

STANDARD END CAP(Good heat transfer to nozzle)

ISOLATION TYPE END CAP(Poor heat transfer to nozzle)

SafetyBurning out of the Synventive Nozzle in any manner such as torching, oven baking, salt bath or fluidized bed at temperatures above 371°C [700°F] will cause the Heat Pipes to become inoperative and voids the warranty. Also, excessive heating at temperatures above 649°C [1200°F] would cause a non-repairable rupture in the nozzle body.

GENERAL SPECIFICATIONS

All standard Synventive Nozzle bodies are of the removable tip type and are manufactured from 4140 alloy steel.

Maximum Operating Pressure 40,000 PSI (2,758 bar).Maximum Operating Temperature 343 °C [650 °F].Maximum Allowable Temperature 371°C [700°F].Heat Pipe Fluid/Vapor is Non Toxic.

CB7MN7PRDMMNNA3

Nozzle Filters

Recommended for use whenever a high quality filtered melt is desired, e.g., whenever processing with a hot runner system. Also, the use of filters is highly recommended whenever regrind is added to virgin resin and when mold cavity gates are very small.

Synventive Nozzle filters offer a simple, effective, and low cost way of preventing tramp metal and other contaminants from clogging gates or entering the mold. The channel and groove configurations of the filter insert have been optimized for maximum flow at minimum pressure loss.

These filters are available with Synventive Nozzles or can be ordered separately and simply installed into any conventional nozzle with a 12.7 mm [.50”] or 19 mm [.750”] bore.

Installation

To install Type F (small) Synventive Nozzle filters, simply ream a 14 mm [.551”] dia. C’bore at the tip end of any standard removable tip nozzle with a 12.7 mm [.500”] bore. The ream should be 0.4 mm [.015”] deeper than the length of the filter (see chart).For Type F-BIG (large) nozzle filters, for use with nozzles with 19 mm [.750”] bores, ream a 22.2 mm [.875”] dia C’bore.

Removable Tips - Steel and BeCuRemovable Tips for Synventive Nozzles are available in tool steel or Beryllium Copper. The Beryllium Copper tips will operate at a higher temperature than the tool steel tip and should be used when tip freezing is a problem.This will reduce the need to raise the nozzle temperature excessively to solve tip freezing problems.

There are two internal configurations of removable tips:general purpose and nylon.

Nylon Type Tip

Removal and Cleaning

All Synventive Nozzle filters may be removed by simply unscrewing the removable tip at operating temperature and rotating the injection screw. To clean the filter, remove the plastic from the insert by using any conventional method. Clean filters regularly to ensure continued contaminant-free processing.

WARNING: DO NOT USE HIGH PRESSURE INJECTION TO FORCE DIRTY FILTER TO EXTRUDE FROM NOZZLE!

FILTER TYPE PART # GROOVE A* B** Fill Rate ***

F 18-3-99-463 0.5mm [.020”] 82.55 mm [3.250”] 82.17 mm [3.235”] 20 gm/sec

F 18-3-99-471 0.7 mm [.028”] 45.36 mm [1.786”] 45 mm [1.771”] 80 gm/sec

F-BIG 18-3-99-206 0.7 mm [.028”] 101.6 mm [4.000”] 101.5 mm [3.995”] 140 gm/secF-BIG 18-3-99-190 1.32 mm [.050”] 101.6 mm [4.000”] 101.5 mm [3.995”] 280 gm/secF-BIG 18-3-99-242 2.54 mm [.100”] 101.6 mm [4.000”] 101.5 mm [3.995”] 330 gm/sec

Filter element can be inserted either end first GROOVE SIZE

* Dimension A is the depth of the ream from the tip seat.** Dimension B is the overall length of the filter element.*** Maximum fill rate of each Synventive Nozzle varies depending on the melt of index of the material beingprocessed. These capacities are for “easy flow” materials in medium cavities. For highly viscous materials orlonger cavities, the fill rate will be less.

Machine Nozzles Special Features & Accessories

General Purpose Tip

CB8MN8PRDMMNNA3

Mixing Elements

Recommended for use in color mixing applications on large parts, the Synventive Type M-BIG Mixing Element is available with Synventive Type BIG Nozzles greater than or equal to 300 mm [12 inches] in length. They can also be ordered separately and simply installed into any conventional nozzle over 300 mm [12 inches] long with a 19 mm [.750”] bore.

WARNING: DO NOT USE HIGH PRESSURE INJECTION TO FORCE ELEMENT TO EXTRUDE FROM NOZZLE!

__________________Part No. 18-3-99-241__________________

Removal and Cleaning

Synventive Type M-BIG Mixing Elements may be removed by simply unscrewing the removable tip at operating temperature and rotating the injection screw. To clean the element, remove the plastic by using any conventional method.

Spare PartsBand Heaters Thermocouple

ID WIDTH WATTSPART NUMBER

SYNVENTIVE NOZZLE Part no. 83-10-048, Type J (shown)120V 240V

2 1 350 81-20-102 81-20-104 Type AP, M, FPart No. 83-11-048, Type K

2.25 2.50 1000 81-22-124 81-22-125 Type BIG

Type “AP” Nozzle Tips Type “BIG” Nozzle Tips

PART NUMBER DESCRIPTION RADIUS ORIFICE PART NUMBER DESCRIPTION RADIUS ORIFICE

19-2-1-5-5-00 Steel 12.7 [.500”] 3.18 [.125”] 19-6-1-5-7-00 Steel 12.7 [.500”] 3.18 [.125”]

19-2-1-5-5-02 Steel 12.7 [.500”] 4.74 [.187”] 19-6-1-5-7-02 Steel 12.7 [.500”] 4.74 [.187”]

19-2-1-5-5-06 Steel 12.7 [.500”] 9.53 [.375”] 19-6-1-5-7-06 Steel 12.7 [.500”] 9.53 [.375”]

19-2-1-7-5-00 Steel 19 [.750”] 3.18 [.125”] 19-6-1-5-7-20 Steel 12.7 [.500”] 4.74 [.187”] Nylon

19-2-1-7-5-04 Steel 19 [.750”] 6.35 [.250”] 19-6-1-7-7-00 Steel 3.18 [.125”]

19-2-2-5-5-00 BeCu 12.7 [.500”] 3.18 [.125”] 19-6-1-7-7-02 Steel 19 [.750”] 4.74 [.187”]

19-2-2-7-5-00 BeCu 19 [.750”] 3.18 [.125”] 19-6-1-7-7-06 Steel 19 [.750”] 9.53 [.375”]

19-2-1-5-5-06 Steel 12.7 [.500”] 9.53 [.375”] 19-6-1-7-7-20 Steel 19 [.750”] 4.74 [.187”] Nylon

19-6-2-5-7-02 BeCu 12.7 [.500”] 4.74 [.187”]

19-6-2-7-7-02 BeCu 19 [.750”] 4.74 [.187”]

19 [.750”]

CB9MN9PRDMMNNA3

Start-Up

Sufficient soak time must be given to allow the Synventive Nozzle to reach operating temperature prior to operation.

1. If the Synventive Nozzle is already in thecold barrel prior to start-up, then thenozzle will reach operating temperatureat nearly the same time as the barrel. It is good practice to have the nozzle tip away from the mold during warm up. Ifpossible, check the condition of theplastic in the tip of the nozzle. This wouldbe the last portion to soften and is adirect indication that everything is up totemperature.

DO NOT USE OXY-ACETYLENE EQUIPMENT ON SYNVENTIVE NOZZLES!

2. If the Synventive Nozzle is threaded intoa hot barrel, there will be a waiting time,depending on the length of the nozzle,until the operating temperature isreached (see installation procedure,page MN8).Nozzles under 250 mm (10 inches) longwill generally take 15-20 minutes toreach operating temperature, nozzles250 mm [10 inches] to 533 mm [21inches] will take 20-40 minutes to reachoperating temperature.

Machine Nozzles Start-up and Operation

CB10MN10PRDMMNNA3

TroubleshootingMost processing problems with all injection machine nozzles are associated with the tip. The following application rules will avoid potential trouble in this area.

1. For good sealing and minimum heattransfer between the spherical radius onthe tip and the mating bushing, the radiishould be slightly mismatched such thatthe contact will occur only around theorifice.

2. The orifice of the nozzle should alwaysbe slightly smaller in diameter(approximately 1/32”) than the orifice inthe cold sprue bushing. If the orifice inthe tip is larger than the orifice in the cold sprue, then the frozen plastic in the tiporifice cannot be injected out through the small sprue orifice, and it will appear that the tip is operating too cold.

Occurrence of a Cold Nozzle1. Check machine barrel end and adapter, if

applicable, to ensure proper processingtemperature for the plastic beingprocessed.

2. Measure temperature of nozzle at thewrench flats and again at approximately1” back from the tip end.NOTE: DO NOT MEASURE ACTUAL TIPTEMPERATURE. REMOVABLE TPS AREDESIGNED TO OPERATE AT LOWERTEMPERATURES TO PREVENTDROOLING.Nozzle temperatures should be 15°F-25°F lower than barrel/adapter.

3. With nozzle away from mold, make an air shot to confirm nozzle tip is notobstructed and nozzle tip is up totemperature. Tip heating by propane gastorch or hot wire may be used for thisstart up.DO NOT USE OXY-ACETYLENEEQUIPMENT ON SYNVENTIVENOZZLES.If tip continues to freeze between cycles,check the following:

* Tip Orifice - increase diameter (largersprue orifice may be needed).

* Tip Type - if processing Nylon or othercrystalline materials, tip must be “NylonType” (unless nozzle tip is used with ahot sprue bushing or hot runnersystem). Also, Synventive Nozzle Typeswith heater must be used for processingnylon.

* Temperature - increase machine barrelend and/or adapter temperature until tipis self-opening.

* Tip Material - change to Beryllium Copper tip.Beryllium Copper tips will operate athigher temperatures than steel types.

3. Increasing the tip orifice has a strongimpact on the ability of tips to be selfopening, slower to freeze, and willreduce the resistance to plastic flow. Forthese reasons, it is always advisable touse the largest possible orifice in thenozzle tip.Note: When nozzle tips are used againsthot sprue bushings or hot manifolds, the orifice need not be restricted in any wayand can be sized to match the bore in the hot bushing. If the nozzle tip orificediameter is significantly smaller than thehot runner inlet bore, a “dead area” iscreated. This dead area can possiblycause prolonged color changing ordegradation of time/temperaturesensitive materials.

4. Be sure the rear opening of theremovable tip matches the bore diameter of the nozzle.

5. If using a hot sprue bushing or notrunner system, sprue break is notnecessary. It may cause undue wear tothe nozzle tip or inlet seat.

HOT

Nozzle Tip

Hot Runner System Inlet

GOOD BAD

GOOD BAD

Machine Nozzles Troubleshooting

CB11MN11PRDMMNNA3

Machine Nozzles Worksheet

Att.: Fax:

This worksheet needs to be filled out completely. Information not applicable, please fill in N/A.

Customer information

Company Machine Type:

Address: Model # & Size:

Nozzle Style:

Contact: Length:

Tel: Thread Size:

PO#:

How To Order

1. Choose appropriate Synventive Nozzle and tip for application. Does your machine screw tip protrude into the nozzle rear opening? Yes No

For Nozzles specify: Stainless steel nozzle body?

Nozzle type (“AP” etc.), with or without filter (if filter is ordered, specify groove size) and material (4140 alloy steel or stainless steel)

Yes No

Required Thread Dimensions:

“M” “G”

Nozzle length (“L1”)Standard 1.62” (41.1mm)

“X”

Nozzle thread size “S” Angle

Type of molding machine (machine maker) “H” “F”

Tip style (standard or nylon) and material (steel or BeCu) “J”(if applicable)

Heater band voltage (120, 208 or 240 volt)

For Nozzle Filters specify:

Type “F” or Type “F-Big”

Groove size

For Removable Tips specify:

“AP” or “BIG” tip

Steel or BeCu

General purpose or nylon tip

Radius (12.7 mm [.500”] or 19.05 mm [.750”]) Tip Specifications: (Nozzle tip not included)

Orifice (“AP” Tip - 1/8” or 3/8”; Tip Style: G.P. Nylon

“BIG” Tip - 3/16” or 3/8”) Material: BeCu Steel

Radius: 12.7 mm [.500”]2. If your nozzle application differs from those listed in the selection

guide, fill out the application worksheet as complete as possible and return it to Synventive.

19.05 mm [.750”]

Orifice Diameter: 3.2 mm [1/8”]

4.8 mm [3/16]

9.5 mm [3/8]

3. To place an order or for more information: Nozzle Type: “AP” “M” “F”

Call Toll Free 1-800-367-5662 “BIG” “M-BIG” “F-BIG”

Tip Threads: 7/8-14 (AP) 1 1/4-12 (BIG)

Required Voltage: 120V 208V 240V

Special Requirements (if any): Nozzle Thermocouple: (not included)

1/4-28 (Synventive Standard)

Other

Specify: Type “J” Type “K”